Forming Simulation of Woven Composite

Fibers and its Influence on Crash

Performance
Dr Subir Roy
Senior Director, Industry Solutions
Innovation Intelligence

Altair

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Outline

Product Overview
Study Objective
Manufacturing processes
Process simulation
Mapping fiber orientation to crash model
Crash simulation results
Additional options

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Altair Manufacturing Solutions

Stamping

HyperForm
(HW)

Extrusion

HyperXtrude
(HW/Inspire)

OptiStruct / HyperStudy

Casting

Click2Cast
NovaCast
(APA)

Injection
Molding

Moldex
(APA)

Mapping

HCRM (HW)
Converse (APA)

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HyperForm: Advanced Solution for Sheet Metal Forming

Early feasibility analysis
Material cost analysis
Die face design

Virtual try-out and process optimization

Press hardening
Die stress analysis and topology optimization
Composite forming
Initialization of structural CAE models

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Objective

1. Double Dome simulation of a composite weave [Ref. NUMISHEET05]

2. Map fiber orientations from forming to crash model
3. Crash simulation to check influence of fiber orientations

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Composite Forming Process: RTM

Ref. CAMX 2014

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Composite Forming Process: Thermoforming

Ref. CAMX 2014

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Forming Simulation Model

Blankholder force : 350N
Initial blank size : 290mm * 190mm
Tool speed : 170mm/sec
Blank

Punch

Die
Blankholder

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Weave Material Properties

1 layer of a Balanced Twill weave
Stiffness behavior is non-linear in both warp and weft directions

Shear stress is a function of shear angle

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Forming Simulation Results

Shear angles at 13 points

Maximum shear angle = 36,9

Consistent with shear stress distribution

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Forming Simulation Results

Stress and strain in warp direction

Stress and strain in weft direction

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Crash Simulation Model

Final fiber orientations are mapped on a coarser crash mesh using
HyperCrash Results Mapper (HCRM)
800mm/sec

Rigid wall
Rupture criteria : Hashin failure
Maximum stress value in direction 1 and 2, tension and compression

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Crash Simulation Results

Normal resultant force against rigid wall shows a significant difference

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Summary
Fabric material law in RADIOSS is able to model composite weave forming
Physical behavior such as non-linearity of stiffness for warp and weft direction,
shear stress as a function of shear angle are modeled

Final fiber orientations can be mapped to crash simulation model

Fiber orientations resulting from stamping simulation influence rupture mode and

stiffness response for crash simulation

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Rapid Drape Estimator for Composite Fibers (13.0)

Calculate

Fiber orientation (draping) angles

Thickness variation

Interfaces

OptiStruct

Nastran

HM Drape Estimator (white) versus competition (red)

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Rapid Drape Estimator for LSDyna (14.0)

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Advanced Meso-scale Modeling of Draping

Model bands of woven fibers using shell elements

Model individual woven fiber using solid elements

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Advanced Meso-scale Modeling with Resin

SPH to model resin flow

390 000 nodes

320 000 SPH cells

6 h on 24 CPUs
CPUs (Troy Cluster)

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Coupling Macro and Meso-scale Modeling

Macro-scale model

Meso-scale patch at critical area

Maximum shear angle region

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Indirect Coupling of Macro and Meso-scale Modeling

1.

Forming simulation at macro-scale

2.

Map the meso patch boundaries on the flat mesh

3.

Extract the displacement history at boundaries

4.

Simulate meso-scale model with displacement history

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Design Optimization Cycle

Forming:
(HyperForm)

Weave layup:
(CEDREM/HyperMesh)

Design changes :
HyperMorph,
HyperStudy

Mapping
(HWRM )

Performance
(OS/RADIOSS)

OK?

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Thank you